Fundamentals of DESIGN AND MANUFACTURINGPRESCRIBED SYLLABUS FUNDAMENTALS OF DESIGN AND MANUFACTURING (AD-301/AN-201) Group A Engineering design process and its structure. Identification and analysis of need, product design specifications, standards of performance and constraints. Searching for design concepts; morphological analysis, brainstorming. Evaluation of design concepts for physical reliability, economic feasibility and utility. Detailed design; design for manufacture, assembly, shipping, maintenance, use, and recyclability. Design checks for clarity, simplicity, modularity and safety. Standardization and size ranges. Reliability and robust design. Design organisation and communication, technical reports, drawings, presentations and models. Concept of manufacturing; classification of manufacturing processes. Fundamentals of casting. Basic understanding of commonly used casting processes (sand casting, investment casting and permanent mould casting processes). Fundamentals of metal forming]; hot and cold working; basic understanding of primary metal forming processes (rolling, forging, extrusion and drawing processes, punching and blanking). Group B Fundamentals of metal cutting; tool-work interaction for production of machined surfaces. Classification of machining processes. Basic machining operations (turning, shaping, planning, drilling and milling processes). Fundamentals of grinding and finishing; overview of unconventional machining processes; fundamentals of welding processes; introduction to primary welding and allied processes; selection of manufacturing processes. Design for manufacturability.Need ‘for integration— commercial, economic and technological perspective; basic tools of integration; concept of a system. Introduction to information technology and its elements, Introduction to group technology; introduction to simulation and database management systems. Elements of integration—controllers, sensors, robots, automated machines; AGVs, AS, RS, etc. Product and process design for integration; design for economic manufacturing; design for manufacturing integration. Introduction to computer aided process planning; selection of machine tools. www.goamit.inCNeed > Market analysis Specifications Conceptualization lt Concept selection evaluating alterna and ives . Analysis Experimentation and prototyping Marketing and sales Fig. 1.1 Design processMorphology of design: Refers to the study of the chronological structure of design projects. The following phases are usually involved in any design project: (a) Feasibility study (b) Preliminary design (c) Detailed design (d) Production Planning (e) Distribution planning (f) Consumption planning (g) Retirement planning Design process: The design process is a sequence of events that help to define the stages of design and unfold the design in a systematic manner. Fig. 1.1 shows various steps in designProduct Development Processes — T +__ io Clarify the task 2/8 - Elaborate the specifications Ble gle s s f Specifications Identify essential problems Establish function structures Search for solution principles Combine and firm up into concept! variants Evalute against technical and economic criteria ubisap Tendeoucg Concept generation Concept selection Develop preliminary layouts and form designs Select best preliminary layouts Refine and evaluate against technical and economic criteria Preliminary layout anosdu! pue apeiBdn ubisep juaWIpoqWy Optimize and complete form designs Check for errors and cost effectiveness Prepare the priliminary parts list and production documents 5 < Definitive layout 7 i Finalize details Complete detail drawings and production documents Check all documents (from Poh!) Fig. 2.1. Six phases of generic product development process. aidiounid eu yo uoneziwindo2.3 Product Development Process ‘a Generic Development Process) A process is a sequence of steps ee ee is me inputs into a set of outputs. A product deve eerie empl Sequence of steps or activities that an ent € A ae vs to conceive, design and commercialize a pro ine ao y ee steps are intellectual and organizational rat! er a cay Some organizations define and follow a precise a etailed development process, while others may not even be able to describe their processes. Every organization employs a Process slightly different from other organization. In fact some time one organization follow different process for different product development projects. For a success the process must be well defined. Reasons for a well defined process : 1. Quality assurance 2. Co-ordination, 3. Planning 4. Management 5. Improvement. A generic development Process mainly consists of six phases as shown in the Fig. 2.1, the development team, indentifying customer ees needs specifications. Conce > €Stablishi ct Pt generar; ablishing produ 7 on i through which product, Provides q as concept selectiog for the product and SP€cifies the b ‘Ic functional descriptio: The product launch o¢, curs When th, Usiness goals of the effort: for purchase in marketplace. © Prodiict becomes availableThe six phases of generic (genius) development Proce, are: 0. Planning. It is also known as zero phase Since j Precedes the project approval and launch of the actual Product development process. This phase begins with corporate Strate, and includes assessment of technological developments and Market objectives. The output of this phase is project Mission Statement, which specifies the target market for the product, business goals, key assumptions and constraints. 1. Task. It is necessary to fomulate a clear, exact Statement of the problem in engineering words and symbols, 2. Specifications. Specifications are important to a Successful design and may be considered that last step in defining the problem. Specifications describe what needs to be achieved in a measurable quantity rather than describing a qualitative desire expressed at the objective stage. In this step we establish the target specification of the product. : 3. Concept development. In this phase of concept, the needs of market are identified, alternative product concepts | are generated and evaluated and a single concept is selected for further development . 4. Preliminary layout. At preliminary layout stage we optimize and complete form designs, check for errors and look into cost effectiveness. 5. Detail design (Definitive layout). The detail design phase includes the complete sg, ifi r standard parts to be purchased from suppliers. A process plan is established and tooling is designed for each part to be fabri i specifications of the purchaseq Parts, the fabrication and assembly o an f the product.Mission Statement Establish] Setting Planning ol identity |} Target pace Concept | | |concept{, | final Remaining Needs | | -SPect- Praaicia eneration”|Test and| | specifi- Develop- fications ISelection) | cations | | ment Product Perform Economic Analysis CONCEPT DEVELOPMENT PHASE. ————————+] Fig. 2.2 Concept development : The front-end activitiesIdentity opportunities Completion ot pre-project Planning Mieeion statements process Fig. 3.1 Product Planning Process Mission Statement : Mission statement is a document summarizes the direction to be followed by the product development team. It may include some or all of the following information. (a) One sentenced description of the product (b) Key business goals (od Target markets (@ Assumptions and constraints of all the people affected by the design process. (2) Stake holdersMission Statement identify | | Establish | | Generate | | Select a Test —e| customer fe|target Spe--} Product | +) Product [=| product Needs. | | cifications | | Concepts | | Goncept | | concept Analyze Perform [Competitive Economic Products ‘Analysis Fig. 4-1. The customer need activity in relation to other concept development activities1ement. ‘he tive steps are. alts 2. 3. Collection of raw data from customers. Interpretation of the raw data in terms of customer needs Organization of needs into hierarchy of primary, secondary, and tertiary needs (if needed). . Establishing of relative importance of needs. . Reflect and review of results and process.: Water purifier set . penaie a list of design objectives: (a) Cost effectiveness (b) Safety (c) Can detect chemical imbalance ? (a) Fewer repairs (e) Easy to repair when needed (/) Long lasting (g) Affordable (h) Low damage ()) Low or no contamination () Takes up least possible space (k) Safe for humans () Safe for environment (m) Gets the job done (n) Can correct problems in least time ? (0) Low maintenance (p) Cleans high volume of Water (qQ) Efficient, etc,Step 3 : Prepare objective tree Water Purifier | | | Safety Cost effectiveness] [Efficiency | | y Safe for Safe for | [Afforadable Low environment| | operators | | to produce | |maintanence | | y Pollutant ] [Any chemicals] [inexpensive | | Afforadable disposed | are connected material for consumer properly 1. m Easy to repair [Does the job?] Y Time to Detect chemical] correct problems| imbalances Fig. 4.3 Objective tree for water purifier.he following points are to be remembered while preparing the specification of a product : (@ Avoid ambiguous phrases. (i) accuracy of specificat (ii) ibility for incorporating improvements at later ie Su (iy) Ascertain that specification is s reasonablener assigned tolerances. (Y. Ascertain that the given specification _ and concise. Besides the above mentioned points, specifications may also include the following : imitation during erection 1 ufacturing constraintsTable 5.1 Need Analysis for a plastic toy rocket ware Need /Function | Design feature Hard 1. Ability to fy | (@ Aerodynamic in shape Plastic molded shape (b) Should have energy source | Battery/Cell to drive to propel a propeller through] small motor to revolve tiny electric motor propeller 2. Durability | Impact resistance material Unbreakable plastic colour 3. Aesthetics | Attractive colour Blinking Pleasant looking colour | lights to be provided / 4. Safety Need | Avoidance of sharp corners Proper chamfers and radius to be provided on mold 5. Low Cost Cost being one of the specifications the cost not to exceed Rs. 500/- ] iMission Statement Identify | | Establish | | Generate Select a Test Refine >] Customer }>|Target Spe--+} Product Product f+} product |=] Specifi- Needs | |cifications| | Concepts} | Concept concept cation Development Plan Analyze Perform Plan Re- Competitive Economic maining Products Analyses [Development cs Project Fig. 6.1 Two stages in which specification are established.Concept Generation and Concept Selection — 2. Search ternally : ext 1. Clarify the Problem : * Understanding * Problem decomposition * Focus on critical subproblems 1 ‘Subproblems 3, Search Internally = Lead users Experts Patents Literature Benchmarking Existing Concepts 4, Explore systematically : *" Classification tree * Combination tree Integrated Solutions 5. Reflect on the Solution and the Process : * Constructive feedback * Individual * Group New Concepts Fig. 7.1 The Five step concept generation methodologyqQ) (4) (5) : Distinguish between brainstorming and Synetics Brainstorming The problem is defined clearly to the group members. However, the members aware of the actual problem during the session. Analogy is not used The human brain is treated asablack box and the extend of stretching of imagination is limited. The group comprises subject related individual. Criticism of all types is discourged, wild, ideas are welcomed. ‘Synetics The problem is not stated directly to the group members. However, the members aware of the actual problem during the session. Analogy is used such as symbolic, personal, direct, fantasy ete Human brain is treated as a glass box and imagination is stretched to a maximum. A live scientist is also present in a synetics group. Synetics generally leads group member towards the problem's solution and wild ideas are not welcomed.Optimal design process comprises three basic design phases: () Conceptual design phase. (ii) Preliminary design phase. (ii) Detail design phase. (5) Conceptual Design : At conceptual design stage, we translate the customer requirements into engineering specifications to generate schemes of design alternatives or feasible designs possible. Following are inputs, tasks involved and output at this stage. INPUT e Customer requirements e Revised problems statement ¢ Initial list of final objectives e Initial list of constraints, e Initial list of principal functions TASKS e Establish functional specifications e Establish means for functions e Write limits of constraints e Develop metrices for objectives e Generate alternative designs ¢ Refine alternatives e Estimate design alternatives e Choose a design concept OUTPUT e Chosen design e Analysis test and evaluation for chosen design.9.2 Economic Feasibility design team, often with the support of Is an economic model for the new pr« to justify continuation of the overall to resolve specific trade-offs amongs, 's and manufacturing costs. While econo’ analysis is shown as one of the later activities in the concept development phase, an early economic analysis will always be performed before the project even begins.yactors that Determine Product Cost 9 2 roduct's total cost C,is computed ag =N(M+L+R)+T+S+pD =Total number of units, m= Mate, = Labour cost /unit, T oll Tial cost/unit = Tooling cost gs = Overhead or indirect Cost, D = De nese i ‘velopment cost The total cost of components given in equation a gnown in Fig. 9. 1. Product design cost are [Capitalization and tooling cost | Total roduct ization and tooling cost otal product Keel development costs Testing and evaluation cost Overhead cost ~ | Direct and variable material cost Total ———— Total Product i cost manufacturing cost Direct and variable labour cost Direct and variable manufacturing cost ——e or Marketing and sales cost Administrative cost Fig. 9.1. Components of total product cost. 94 Life Cycle Cost i t Life cycle costs are over all costs of producing the produc “using for its entire life. Life cycle cost er costs Manufacturing cost Ussree LUD Process of determining or minimum value ofa Bowe a timization : It is defined as the a nditions that gives the maximum notion. 4 i optimization theory : The specific nique, and procedures used to decide on th ean in a defined set of possible alternatives watisfY a selected criterion. methodology € one specific that will best Probabilistic design : Design methods involving with more versatile mathematical systems which takes into consideration both mean value and variance for the parameters. Proof test : These tests indicate the degree of variability and also to identify the failure modes and weak links in the design. Qualifying design concept : It signifies the validity of the design idea. The validity comes only after selecting the best solution, preparing a suitable model and testing it thoroughly to conclusively establish. . Sensitivity analysis : The analysis determine in factors most critical in economic decisions in order toc a ' Uncertainity. With the help of computers this analysis "come more practical. ized system of Value analysis : This is an, OT gan oageary costs ques for identifying and removing ie of the design. ‘out compromising the quality and reliability also known as value engineering. techni tis -arANea vith a view to have a product which c: ee high maintainability results in er machine. Pr Maintainability criteria in design aims at designing ‘an be maintained with eater availability of the Maintainability criteria has two aspects : () The ability of equipment to meet operational objectives with a minimum expenditure of maintenance effort under operational environmental conditions in which scheduled and unscheduled maintenance is performed. (i) Quantitatively, the probability that an item will be restored to specified conditions within a given period of time when maintenance action is performed in accordance with prescribed procedure and resources. 10.2 Maintainability-Definition Y “Maintainability is a characteristic of | design and installation which is expressed as the probability that an item will conform to Specified conditions within a given period of time when maintenance Action is performed in accordance with prescribed procedures and Tesources,” Availability : Availability means proportion of time for which ©quipment or item is available for operation. Thus, maintainability is one of the two ‘design factors associated with equipment’s availability, the other is reliability. ‘—— 12.1 Embodiment Design or Product Layout The word ‘Embody’ means “to give something a tangible expression”. Embodiment designis that part of the design process in which starting from the concept of a technical product, the design is developed, in accordance with technical and economic criteria and in the light of further information, to the point where subsequent detail design can lead directly to production. The general objectives of embodiment design are : () Fulfilment of the technical function ; (i) Econoniic feasibility ; and (i) individual and environmental safety. In many cases several embodiment designs or layouts are needed before a definite design is found and appropriate and desired solution can emerge. 12.2 Detail Design Detail design is the third phase of morphology and it is concerned with arriving at final drawing of any product. It may be an assembly, sub-assembly components and parts of theSuspended Mass —>} Unsprung Mass —>} Orifice Diameter —~| Suspension Performance Spring Constant —>] Dynamic Model of (Analytical) > Attention at 10 Hz +> Estimated Monsterg's Oil Viscosity —1 Support Geomtry | Material Properties —>] Tube Geometry >} Mounting Points >] Static Model of Brake Mounting Stiffness (Analytical) +> Lateral Stiffness Fork Geomtry >| Material Properties >} Fastening Methods >] Suspension | Fatigue Model of Suspension Durability (Physical) [> Cycle to Failure Geometry Fig. 12.2 Models used to access technical feasibility. Technical models may be analytical or physical approximates of the product concept.12.8 Types of a lly classified along two Prototypes can be uselu! e to which . . : A the degre a dimensions. The first dimension 18 © ‘cal prot prototype is physical as opposed to analytical. Physical prototypes te the product. Aspects are tangible artifacts created to approxima Saami of the product of interest to the development team ally built for testing and experimentation. Examples of physical prototypes include models which look and feel like the product, proof-of-concept prototypes used to test an idea quickly, and experimental hardware used to validate the functionality of a product. Analytical prototypes represent the product in a non- tangible, usually mathematically manner. Interesting aspects of the product are analysed, rather than built, Examples of analytical prototypes include computer simulations, systems of equations encoded within a spreadsheet, and computer models of three-dimensional geometry. The second dimension is the degree to whicha prototype is comprehensive as opposed to focused, Comprehensive prototypes implement most, if not all, of the attributes of a product. A comprehensive prototype corresponds closely to the everyday use of the word prototype, in that itisa full-se, .. full operational version of the product, An exam as uly comprehensive prototype is a beta Prototype given to es ie of a in order to identify any remaining design fla ‘ustomers committing to production. In contrast to come beforePhysical Beta Prototype Ball Support o Oo 9 O Prototype Alpha Final Prototype Product Trackball Mechanism Linked to Circuit Simulation Focused Comprehensive ° Simulation of Uiacball Not Generally ici Feasible Equations Modelling Ball Support Analytical Fig. 12.3 Types of prototypes. Prototypes can be classified according to the degree to which they are physical and the degree to which they implement all of the attributes of the productENGINEER 8 CHIEF DRAFTSMAN DESIGNER, Specification, design and development DRAFTSMAN i Assembly Drawings Detail drawing for cast parts, forged parts, welded parts, sheet-metal parts, jigs, fixtures, tools, etc Fig. TRACERS ¥ CHECKERS Y APPROVAL BY DESIGNATED AUTHORITIES ¥ Reproduction, blueprints, etc TO THE SHOPS 12.11 Flow chart of drawing from engineer to shoPS13.2 Objectives of Production and Process Product Topology Chief objectives of production and process product topology are as under : . (i) To prepare a design and manufacturing process that will satisfy both functional and physical objectives at the minimum cost, suitable to the user. (ii) To select the optimum production process which will adapt the design without changing the products performance objectives. (iii) To prepare a simplest possible design as the simpler designs are cheaper, have higher reliability and more easily maintained. Such designs exhibit higher quality and performance in comparison to complex design. (iv) To standardise the various activities like bill of materials, testing, etc. In order to meet the above objectives the following care is to be taken : () Complete drawings must be produced with all the detailed specifications like shape, form, fit, finish, function and interchangeability requirements. (i) The design Prepared should be conductive to the application of economic processing. (iii) Avoid over designing. (iv) Adequate attention is re problems. (Y Selection of the material al optimum ones. (v) Preparation of material list for all components of the product for buying the raw materials, (vi) Prepare a list of the parts which are to be fabricated and parts to be bought from the market, i.e., make or buy decision. equired to measurement of nd process should beCustomer assembly : Customer may tolerate completing some of the product assembly themselves, especially if doing sy provide other benefits. Design and manufacturing process : The sole aim o production and process product topology is to produce a design and manufacturing process for producing a product which will meet the requirement of both functional and physical objectives at a minimum cost acceptable to the consumer. Design for assembly : Design for assembly in simple words can be stated as design of the products with as few partas possible and easy to assemble. Designing for manufacturing : The key concern of DFM is in specifying the best manufacturing process for the component and ensuring that the component form supports the manufacturing process selected. Integration of parts : If a part does not qualify as one of those theoretically necessary, then it is a candidate for physical integration with one or more other parts. , Mechanical working of metals : It is performed to reduce the original block into designed shape, to refine grain size am to control the direction of flow lines. Standard materials ; The materials confirm to various standards such as formed by Govt or a s mi te ahace, size Se an agency. Standard:Clarity : Tt is the Tack of ambiguity of a design, Taciltagg reliable prediction of the performance of the end product and in many cases saves time and costly analysis. Embodiment design : This is that part of the design process in which starting from the concept of a technical product, the design is developed. - Safety : It imposes a consistent approach to the problem of strength, reliability, accident prevention and the protection of the environments. Simplicity : It is generally guarantees economic feasibility. A smaller number of components and simple shapes are produced more quickly and easily. ee Simulation : This is a tool for analysing and designing systems. There are many steps in analysing a system. This is used when analytical and numerical methods to find the solution break down. fare : ja Size ranges : It provides a rationalisation of design 4! roduction procedures. ea . ‘Symbolic models : This models represents some ane a product by using words, numbers. A list of parts bill of mat fall into this category.~y Reliability : It is probability that a component tem will satisfactorily perform its intended os. equipment, or s function under given circumstance Reliability allocation : This is defined as the Process of assigning reliability requirements to the components of a system to obtain the overall specified reliability of a system. Robust design : A robust design is one in which the function and performance of the I are relatively insensitive to variations in any of Series network : This network represents a two independent unit system whose components are connected in series. sroduct or proc noise factors,16.2 Ergonomics . aes ‘Ergonomics’ is aes fom ong presk Wor the laws 9; - Today, i" ‘ ; ‘omos’ and means tl itis See science of fitting the job to enieiy _ concerns the field of the human nae: cee 7 Workin, environment. It can therefore be seen that 1 re ety Wide field, and may be applied at the initial design stage 0} Produc, design. ; , The areas of study covered under ‘ergonomics’ are Anatomy, Physiology and Psychology on one hand and Physics, Mathematics and Design on the other. This is illustrated Fig. 16.1. Physics Psychology = . Materials Engineering & Ergonomics Physiology oe Sciences Design io Mathematics Anatomy Fig. 16.1 Ergonomics linking the engineering and human sciences 16.3 Ergonomics—Definition and Scope Ergonomics may be defined as a science which deals with the systematic study of the relationship and interaction betwee" man, machine and working environment. Here by ‘environment’ we mean not only the ambient environment in which a man works, such as, temperature “humidity, noise level etc., but also his method of work am relationship within the group. The subject, therefore, relates to: * (1) himself ; (2) his ability,"Reasons of stress : Reasons of stress in humans are igen aS under : @ Work overload (job requirements excess capacity) or work underload (due to lack of any intellectual input, or lack of opportunity to use individual’s expertise and skills or job or repetitive nature). (i) Occupational change. (ii) Occupational frustration. (i) Factors, such as high noise, poor lighting etc. 16.9 Human Errors It has been observed that most of the equipment failures take place mainly due to human failures or errors. Hence we see that the overall reliability of a system is adversely effected as humans have some probability of performing their tasks incorrectly. The main reasons of human error are given below : () Inadequate training or skill (i) Tendency to do a thing in diverse ways (ii) Poor equipment design (i) Improper tools (J Inadequate lighting (ui) High noise (vi) Dusty and warm environment (vii) Inadequate work layout (ix) Crowded work space (x) Poor motivation17.3. Components of Communication Cycle The basic elements of all communication Activities a shown in Fig. 17.1. zoo {Source >| Encoding } > Message 1 I 1 @ Feedback Channa ' ' = '---«--1 Receiver /—] Message | -~*— Decoding Fig. 17.1 Basic elements of communications system The following are the components of communication cycle: (i) The Sender : The sender is the communicator Who encodes and transmits the message. He is also called as the encoder or the transmitter. The idea or impulse is generated in his mind. (i) The receiver : The receiver is the decoder of the message. He receives the message, decodes it and sends the seedback to the communicator. (ti) Encoding : Encoding means to translate the meaning into arbitrary symbol system which is common to both the communicator and the receiver, (iv) Decoding : Decoding means to translate the arbitrary symbol system into meaning which is common to both the communicator and the receiver. : (v) Semantic Noise : Semantic noise is any interference with the identification and transmission of the intended meaning in the mind of the communicator and the receiver- . (v) Semantic selection : Semantic selection means definite realisation of a Particular idea and its meaning. sion : Signal transmission mea” (vi) Signal transmis. transmit é mS message by the communication. itting the encoded1.1 Concept of Manufacturing Manufacturing is the economic term for making goods and services available to satisfy human wants. It is penerally understood that engineers, design products. However, an clement of this activity that is often timated is the necessity for engineers to design able to making, product. The product design and manufacturing disciplines are closely related because consideration of how a component is to be manufactured is often a defining criterion for successful design, The manufacturing processes are collected together to rm a manufactu ring system. The manufacturing system takes ‘puts and produces products for the customer.4 Classification of a system Systems may be broadly classified as ()) Open loop system (i) Closed loop or Feedback system (i) Open loop system. Fig. 1.2 shows the schematic epresentation of open loop system. This system comprises of the following elements : Inputs >| Processing —~| Outputs unit Fig. 1.2 Open loop system (a) Input (b) Processing unit (c) Output This system does not have any influence of outputs on inputs ie., inputs do not contribute any control on outputs. Some examples of open loop systems are : (a) Watch (b) Metal cutting machine (¢ Metal working machine Note that the watch by itself does not observe its inaccuracy and adjust itself. In the same manner, lathe machine which is used for metal cutting does not adjust its speed, feed etc. according to work. (i) Closed loop or Feedback system. Fig. 1.3 show the schematic representation of a closed loop system. This type of system brings result from the past action of the system and thereby it controls the future action. Processing |______+! Outputs unit Inputs Sensing |__| Computer ——| system — Fig. 1.3 Closed loop systemsy?" 1) Solved problem Pr oblem 1.1 Discuss “Input-output” model. How this model to analyse an automobile industry ? solution. An input-output model basically concerns the ts to be provided to a system; what is the influenc ton the system; what type of inputs are c., similarly the effect of system’s performance sic InP’ egch inpu e system, et oa the output. will you e of demanded by Fig. 1.6 shows production system as an “Input-output” model. We can use this model to analyse an automobile industry. Personnel Hm on a a Good or Engineering | E | Material . services equipments | 2 Transportation and materials | Z . ————+| a cot Finance —"T t--------- »| CONTROL Operation management Non-economic impact OUTPUT Marketing & Public relation |_—__—» Economic impacts to--- +t Fig. 1.6 Production system of input-output Note : For an automo! > - iteration bile industry it is advisable to use lomated manufacture. In order that the automation process be successful, inputs should have proper specifications and Uniformity‘eb and station BTA om TT position or lo ific operations are perform Operations ation is a distinct action performed to produce a or effect. machine operations are loading and Wnloeeeed Operations categorized by function are : (i) ‘Material handling and transporting : Change in position ofthe product. re sing : Change in volume and quality, including assembly and disassembly. (ii) Packaging : May be temporary a permanent for shipping. 1c testing : Comparison to the standard or check process behaviour. (0) Storing : Time lapses without further operations. Treatment : Treatments operate continuously on the Workpiece. They usuaily alter or modify the product in process ithout tool contact. e.g. Heat treating, curing, galvanizing, plating etc. Treatments usually do add value to the part.2.3 Batch production production is the manufactt icles, either to meet a specific o ar or other products. As in job production po! fixtures, and other aids are dependent on tl if the order is to be executed only once. the In batch production, too, three types can be mentioned : 1 _Abatch produced only once. h produced repeatedly at irregular intervals, Here, again, O principal problems arise in’batch production: the size of the batch and the scheduling of production.Materials processing families, subgroups, Gnd typ, 4 ie Processes: = sub group Typical processes [> Sand casting 6 Shell casting [> Expendable mol Investment casting Casting ‘> Multiple use mold —} "> Lost form casting [> Die casting > Permanent mold casing [> Turing [> Milling [> Mechanical i> Drilling machining > Boring L» Sawing Material removal > Etching | Electropolishing ‘> Non traditional | Electrodischarge machining machining [> Water jet machining > Laser beam machining [> Forging Hot bulk forming —1» Rolling Deformation processes Cold forming ——_| www.goamit.in Ly» Extrusion [> Wire drawing I> Swaging | Roll forming ‘> Deep drawing [> Oxyfuel [> Arc Welding» oma Brazin : Consolidation processes Sol ering [> Resistance > Laser Adhesive bonding [> Fasterners Mechani joining =" I> Press fit Le Shrink fitSerle , Hot workingss— Hot canoxting OD Aone at aq la}. ecmwaline dex dee. regarded tin a Siouttaneoun prion ¢° Olefromation and vecowery. 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OD faye. 2D a pholegital_pnethood help p in thentd f YeQuived fuackoolp\ ot o* | Clawify the” “tet jude Sedition oa dent Hf onential pobend A) Develop _preliminayy layouta£ \ an ih Ns_. Soleick eae Paclimitany lewjoucta ry lo ouk) | R oplimixe and complete fo [> | Obnans: checl( for eroy £4 \\ cl eats } 4. (Gearciwemloyoi) Hinalize aelails Compact derailay!* Chanutyg uc Pro Cucion, docu © YeU lo rfIk _—amit_gupta v 192 profile visits in the last 7 days 502 784 81 Posts Followers Following ves Amit Gupta Blogger ® Civil Engineer Varanasi (India) &% 9_April © Always_Smile@®... more www.goamit.in/Today 3:39 AM Guruji, | liked your material Science notes, it is good and comvinient for us, but do you think it is upto the 100 percent mark.... Or pease suggest in the vidio the structure of study plan, how to prepare for amie sec a Appreciated your work op ole dp @a¢daud 03 oO 920S'17: 1 FN: AN 201/AD 301 (1401) FUNDAMENTAL OF DESIGN AND MANUFACTURING Time : Three hours Maximum Marks : 100 Answer FIVE questions, taking ANY TWO from Group A, ANY TWO from Group B and ALL from Group C. All parts of a question ( a, b, etc. ) should be answered at one place. Answer should be brief and to-the-point and be supple- mented with neat sketches. Unnecessary long answer may result in loss of marks. Any missing or wrong data may be assumed suitably giving proper justification. Figures on the right-hand side margin indicate full marks. Group A 1. (a) What do you understand by the term ‘Design by evaluation’ ? Trace the major changes you ob- served over the decade in electric switches. Why these changes are being made ? 8 (0) Briefly describe the following types of customer . needs : “a: ( Direcineess. WWW.goamit.in (ii) Latent needs (iii) Constant needs (iv) Variable needs. (Turn Over )(©) Explain briefly the following Engineering require- ments: 4 (i Functional requirements (ii) Constraints. 2. (@) The problem of urban transport is getting increas- ingly acute with each passing year. Carry out the need analysis for an urban transport system for a metropolitan city. (6) What valuable function does brainstorming a product or product design serve ? 8 (©) Make ashort note on ‘Design for assembly’. 4 3. (@) Write down some of the main considerations that may be used in choosing the casting process for fabrication ofa product. 8 (0) With schematic diagram explain the investment casting process ? Write down its advantages and limitations. 8 (c) Why does grey iron casting requires less riser material than a steel casting of the same size ? 4 4. @) Briefly explain the principle of rolling ? Give example of rolling stand arrangements ? (6) @ Differentiate between coining andembossing 4 (ii) Distinguish between bending and drawing. 4 (©) Whatare the specific merit of cold working over hot working? $°17: 1 FN: AN201/AD301 (1401) 2) (Continued )5. @ () © 6. (a) (2) 7. (a) ® © GroupB What do you understand by the term ‘Drilling’, ‘Reaming’, and ‘Boring’ ? How do they differ from each other ? 8 Differentiate between up milling and down milling. Explain their application mentioning the most commonly used method, 8 Under what condition hydraulic shapers are preferred over the mechanical shaper. 4 With a schematic diagram explain the fundamen- tals of ultrasonic machining process (USM). Why USM is not suitable for material having hardness less than 60Rc. 8 What are the grinding process parameters that are of interest ? Explain their effect on the grinding performance and the wear rates. 8 Discuss the need of edge preparation in welding. 4 What do you understand by the term group technology ? What is the basis of. forming groups in group technology ? What is automated guided vehicle ? What are the various types of AGVS that are used in automa- tion manufacturing? “8 What are the advantages of AS/RS ? 4 8. (@) Briefly explain the classification ofrobots. 8 8°17: 1 FN : AN201/AD301 (1401) (3) (Turn Over )(b) Briefly explain the methodology to be followed for developing a generative type of computer aided process planning system. 8 (©) What is direct numerical control and how it is different from distributed numerical control. 4 Group C 9. Answer the following questions : 2x10 () Whatare the methods of reducing spring back in sheet metal operations ? (ii) Write briefly about mould wash. (iii) What is an Adaptive control ? (iv) Draw relaxation circuit for EDM and label its various parts. Also draw the voltage time curve for the same. (v) What do you understand by term machinability index? (vi) What is Tack weld? (vif) Variant approach to CAPP. (viii) What is redundancy ? Howit effects the reliability ofasystem ? (ix) Write down the Design: for Production Guidelines. (~) Whatis simultaneous engineering ? www.goamit.in $°17: 1 FN: AN201/AD301 (1401) (4) AG-18,000I _amit_gupta ~ 192 profile visits in the last 7 days 502 784 81 Posts Followers Following ws Amit Gupta . . ciegaer Connecting with us.. ~® Civil Engineer Varanasi (India) &% 9_April © Always_Smile@®... more www.goamit.in/